Preshaped form

ABSTRACT

A prefabricated relief form member for use as an architectural trim feature on a structure using structural elements from connected wire assemblies such as corner aid to make a prefabricated relief form member and fastening the structural elements together such as by glue and putting a sheet of paper under the relief form member and applying plaster to form a trim.

RELATED APPLICATIONS

[0001] This application is a continuation in part of application Ser.No. 10/679,720 filed on Oct. 6, 2003 which is a divisional ofapplication Ser. No. 10/679,720 filed on Oct. 6, 2003 which is adivisional of application Ser. No. 10/254,038 filed on Sep. 24, 2202 nowU.S. Pat. No. 6,662,213 which is a continuation of patent applicationSer. No. 08/967,055, filed on Nov. 10, 1997 now U.S. Pat. No. 6,591,566which is a continuation in part of application Ser. No. 08/441,251 filedMay 15, 1995 now U.S. Pat. No. 5,685,116, which is a continuation ofpatent application Ser. No. 08/222,826 filed on Apr. 5, 1994 nowabandoned, the contents of all of which are incorporated herein byreference.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The invention relates to prefabricated, light-weight, plasterrelief forms to provide quick, low cost, installation of support membersfor constructing plaster coated decorative architectural trim elementssometimes called “plant-ons” or “bump-outs” applied to the outside wallsof structures.

[0004] 2. Previous Art

[0005] Ornamentation and decoration of building structures such asresidences and businesses is one important aspect of architecture.Marketing and sale of residences is enhanced by additional decorativedetail. Pride of ownership is also enhanced by improved appearance ofone's building or residence. Ornamentation and decorative details areused extensively to add desirability and attractiveness to structures.

[0006] In certain regions of the country, such as the West andSouthwest, the homes in the Mission style, and the Mediterranean styleare quite popular. One of the popular methods of ornamentation used forthese styles of homes is referred to in the building trades as“plant-ons” or “bump-outs”. The plant-ons may extend for a considerablelength along the horizontal or vertical dimension of a wall or walls ofa home or business. The plant-ons add a band or bands of relief to anotherwise blank facade that is presented by an unbroken expanse ofplaster or stucco. The bands may extend completely around the outsideperimeter of a building. For a conventional home of 2500 sq. ft., thismay amount to 300-500 ft of bands for one single layer. The support forthese bands are generally made of overlapping wooden boards including afirst layer of 2×12 inches and a second layer of 2×8 inches. The boardsare placed end to end in standard lengths of 8 to 12 ft to create acontinuous relief band around the home. Similar bands may be constructedaround door and window openings.

[0007] Attractive relief borders around windows and doors are also usedto provide enhancements to the architecture of homes and buildings. Suchwindow and door borders have been constructed using the above methodsand materials.

[0008] These features are not necessary to the structural integrity ofthe building, but do add a pleasing visual aesthetic appearance to ahome or business.

[0009] One example of architectural relief products for attachment tohomes are pre-shaped foam members such as cornices, bases, sills andbalusters, for example, supplied by High Tech Foam Products, Inc ofCorona, Calif. Foam members may be provided in a wide variety of shapesand sizes. The disadvantage of these members as supports for reliefbands include the expense of the items themselves, on the order of $5 to$6 per linear foot, and the additional labor and material involved inadding a layer of screening or lath material over the foam to provide amatrix for the plaster to adhere.

[0010] A conventional method of construction of plant-ons uses one ormore planks of overlapping boards attached to a wall at a particularheight. To achieve a continuous band or strip of relief, multiplelengths of uniform cross section boards are aligned end to end andattached to the studs of a prepared wall. For conventional construction,the studs must be no more than 24 inches on center, or less, accordingto the applicable local, state or national building codes. Theattachment is done with hammer driven nails, power gun driven nails,large staple guns or the like. The boards are attached to the wall priorto the application of a plaster coat or coats and prior to theapplication of a lath sheeting which will form a matrix or lattice forsupporting the plaster when it is applied. The lath is conventionallymade of chicken wire or expanded metal and attached with nails, staplesor the like. The lath sheeting may be suspended away from the wall andboards by a furring strip or strips interposed between the surface ofthe wall and the sheeting. Self furred sheeting or wire may also be usedto maintain the spacing between the wall and the sheeting. An example ofsuch wire is self-furred metal lath made by California Expanded MetalProducts Company of Industry, Calif. “Dimpled” or ribbed type selffurring metal lath provides a {fraction (1/4)} inch indentation in themetal lath to hold it away from the wall allowing the plaster to fillthe space between, insuring the lath is embedded. The spacing betweenthe lath and the wall or boards provides the opening for the plastercoat to surround the lath and thereby bond firmly to the wall. Amoisture barrier layer, of building paper, for example, is appliedbetween the boards and the lath sheeting by means of staples, nails, anadhesive coating or the like.

[0011] The boards provide the relief pattern or bump-out desired.Additional screening is cut and shaped by hand to conform to theprotruding bump-out and nailed or stapled to the boards and the wall.

[0012] Plaster is then applied to the bump-out and the wall to form thefinished surface.

[0013] With reference to FIG. 10A, there is shown a schematic diagram ofan exploded view of one previous art method of assembly for a manuallyfabricated plaster relief form as described above. A plurality of boardsof desired width with the same cross section are aligned end to end andnailed to the prepared wall to form a continuous plaster relief band tothe desired length. Additional lengths of wire screen or lath sectionsmay be placed over the boards and formed by hand to the contour of theboards. The additional sections are then typically nailed in place. FIG.10B illustrates a cross section of such a relief form having a boardattached to a stud framed wall. A layer of moisture barrier paper andmetal screen or lath are typically placed against the wall and attachedby nails to the studs. A plurality of spacers, such as furring strips ordimples in the additional screen sections, are provided between theboards and the additional wire screen sections to allow the subsequentplaster layer to flow into the openings of the wire screen sections andfill the space between the screens and the top of the boards. Plaster isthen typically applied by hand using a hawk and trowel method or appliedwith a nozzle connected to a machine as described above.

[0014] With reference to FIG. 10C, an additional improvement to theprevious art method is shown. Guide edge members are attached, typicallyby nailing into the form boards, to the edges of the wire screensections over the plaster form boards. The guide edges are spaced apartfrom and aligned to be parallel with the plaster form boards. The guideedge members provide a guide to the trowel or plaster dispensing nozzleas the plaster is applied, thereby allowing a uniform depth of plasterto be applied easily. Representative guide edge members used in thetrade are made from 14 gauge wire such as the “CEMCORNER” cornerreinforcement made by Cemco, Covina Lane, Calif. Or the “CornerAid”cover nose wire made by Stockton Products, Burbank, Calif.

[0015] The above-described method requires a number of hand operations,such a nailing the boards, cutting the additional wire screen sections,hand forming the screen sections over the boards and attaching the guideedge members, which significantly increases the cost of applying plasterrelief bands. It would be an advantage to provide a system to reduce thenumber of hand operations required to apply plaster relief bands.

[0016] It is important to select boards made of wood which are ofuniform cross section, in order to achieve a visually pleasing effect.Boards which are not uniform in thickness or width will show angularoffsets at the ends where they meet. It is also important to select woodwhich is well cured and has stable dimensional shape. If the wood twistsor otherwise deforms after the plaster has dried, unsightly cracks mayappear. Cracks may also allow moisture to penetrate the plaster andattack the wood beneath, or provide additional unwanted access to wooddestroying pests. Boards of suitable quality currently sell for $2 to $3per linear foot. On a double band board structure, the cost could befrom $15 to $18 per linear foot, after including the costs of boards,lath application and finished plaster.

[0017] The use of wood for forming the support structure for the plasterof decorative bands is well known in the trade. As the costs of woodcontinue to increase, and the availability of high quality boardscontinues to diminish, there is an urgent need to provide an alternativelow cost structure which will satisfy the desire for aestheticenhancements to the various stucco and plaster styles of home andoffice.

[0018] The non-uniformity of wooden boards in width and thickness cancause unsightly mismatch in the appearance of the relief bands on ahome. Either higher quality and thus higher cost boards must bepurchased, or labor intensive and expensive modification must be made onthe job site. This slows down the assembly process and further adds tothe cost of building. It would be an advantage to provide a supportstructure for plaster relief bands which would guarantee uniformity incross section aspect and thus match precisely when aligned at the ends.

[0019] The weight of the wood used for the band support structurecreates several concerns. Handling and aligning long lengths of boardstakes considerable strength and capability. Moving and holding a 12 footlength of board may require two workers to align successive boards. Thecost of shipping the wood used in making the band supports is also afactor in the cost of building plaster or stucco homes. Wood often isshipped in a condition wherein it contains an appreciable amount ofwater which significantly increases the weight of the wood. Woodtypically contains 30% or more water by weight. Such additional weightis of no use and in fact may be harmful as described above. Wood usedfor decorative support may also be stored outdoors while awaitingconstruction. It is possible for the wood to absorb moisture from thesurroundings thereby increasing its' weight even if it had been shippedin an originally dry state. It would be an advantage to have a bandsupport structure which is lighter in weight, thereby reducing the costand time of installation and the cost of shipping to the job site. Itwould be an additional advantage to provide a band support structurewhich could not absorb water while stored at a building site.

[0020] The use of wood as a building material combined with increaseddemands from a growing population puts increasing pressure on our forestpreserves. It would be an advantage to provide a substitute materialwhich would reduce the need to use wood except where it is mosteffective, thereby preserving our valuable resources.

[0021] Even though the wood for plant on bands is covered byfire-resistant plaster, the building codes still require the bands to beconsidered flammable structures. It would be an advantage to provide asubstitute material which was impervious to fire, and thereby addincreased safety to homes and buildings.

SUMMARY OF THE INVENTION

[0022] The general purpose of the invention is to provide light weight,low cost prefabricated plaster relief form members which can be shippedto a construction job site in final form to simplify the application ofrelief bands to the exterior of homes and buildings which are to becoated with a cementitous coating, typically plaster or stucco.

[0023] According to one embodiment of the invention a prefabricatedplaster relief form member is provided for receiving and retaining afluid cementitious coating, such as plaster, when the member is attachedto a prepared structural wall.

[0024] The member is configured from an openwork lattice sheet,preferably of an expanded metal lath. The lattice sheet is adapted toreceive and retain the plaster when the plaster when the plaster isapplied by hand or by spraying with a nozzle of a machine. The latticesheet is formed into a longitudinal channel having a top with opposedouter edges.

[0025] Two spaced apart sides extend away from the respective opposedouter edges, to respective base edges. The respective base edges arealigned parallel to the top such that a mounting plane is definedparallel to the top of the channel.

[0026] Two mounting flange portions, each extending outward and awayfrom the base edges of the respective sides, lie within the mountingplane parallel to the channel.

[0027] The member is thus defined as a channel having a length betweentwo opposed ends and a width between the two opposed sides. The channelis configured to have an essentially uniform lateral cross section,perpendicular to the longitudinal dimension, protruding away from themounting plane.

[0028] The flange sections are adapted for mounting to the preparedstructural wall such that a plurality of such members mounted on thestructural wall and adjoined end-to-end form a continuous relief bandprotruding from the wall. The flange sections may be nailed or stapledto the studs of a prepared wall after adjacent form members are alignedand adjoined end-to-end.

[0029] The regular cross section of similar prefabricated form membersensures an aesthetically pleasing effect is easily achieved withoutshaving, trimming or selecting wooden boards.

[0030] The light weight and regular shape of these prefabricated membersenable for easy and low cost installation of the support forms neededfor applying relief bands to stucco homes and buildings.

[0031] The metal lath or lattice work is light, but has sufficientstrength to support the plaster coating and hold it in place while itcures. The prefabricated shape enables the construction of plasterrelief bands without the use of wood boards and the additional weightand shipping cost involved. The cells and strands of the lattice workprovides openings for the plaster to flow and provides a secure networkfor the plaster to take hold while it hardens.

[0032] The uniform shape of the form member is dimensionally stable andnot subject to absorbing water. This eliminates the potential of warpingthat occurs with the use of wood as support members for relief bands.

[0033] The combination of the structural support and the open lattice inthe one element of the prefabricated form member reduces the labor thatotherwise is involved in attaching sheets of screen wire to the woodplanks used in conventional construction.

[0034] In another embodiment of the prefabricated form member, there isprovided at least one edge guide segment parallel to and spaced apart apreselected distance from at least one of the channel outer edges. Theedge guide segment is aligned parallel to the length of the member andis configured to provide a guide edge for a tool. A connecting frame isprovided for rigidly connecting the edge guide segment to the membersuch that the edge guide segment provides a secure guide edge for a toolused to apply the plaster or stucco coating to a preselected thicknessalong the length of the member. A preferred thickness of plaster coatingis about {fraction (7/8)} inch minimum in the finished state.

[0035] The prefabricated form member is typically formed from expanded,galvanized metal having a preformed weight of about 3.4 pounds persquare yard. The lattice is shaped into an array of elongated hexagons,the hexagons having a major axis of about {fraction (1/2)} inch and aminor axis of about {fraction (3/8)} inch. The adjacent hexagons alongthe minor axis being connected at opposed sides by respective commonside segments of about {fraction (1/8)} inch in length, and adjacenthexagons along the major axis being connected at the ends of respective{fraction (3/8)} inch common end segments, while the respective side andend segments are connected by corresponding right and left angledlinking segments.

[0036] A prefabricated form member as described above is non-permeableto water, non-flammable and semi-rigid and has a lateral strengthsufficient to support a plaster coating having a thickness from about ½inch in thickness, to about 2 inches in thickness.

[0037] It is an advantage in accordance with this invention to provideplaster relief form members which eliminate the use of lumber inachieving architectural enhancement effects.

[0038] It is a further advantage in accordance with this invention toprovide plaster relief form members which reduce cost of installation.

[0039] It is a further advantage in accordance with this invention toprovide plaster relief form members which are lower in weight thanequivalent lumber elements.

[0040] It is a further advantage in accordance with this invention toprovide plaster relief form members which reduce the cost of shippingmembers to the job site.

[0041] It is a further advantage in accordance with this invention toprovide plaster relief form members which are uniform in cross sectionand impervious to warping or cracking.

[0042] It is a further advantage in accordance with this invention toprovide plaster relief form members which reduce the number of handoperations and thereby reduce the cost of installation.

[0043] It is a further advantage in accordance with this invention toprovide plaster relief form members which are non-flammable.

[0044] It is a further advantage in accordance with this invention toprovide plaster relief form members which may be mass-produced in a widevariety of standard shapes at low cost.

[0045] It is a further advantage in accordance with this invention toprovide plaster relief form members which can be easily joinedend-to-end to form visually uniform relief bands on outer walls, arounddoor or window openings and along the facia of a building. The reliefbands have stable shape with age and are resistant to warping andcracking due to moisture absorption/desorption.

[0046] It is a further advantage of the present invention to use weldedwire lath to form the form member absent any other structural supportmember.

[0047] It is a further advantage to add edge guides to the welded wireform member.

[0048] It is a further advantage to form the member out of rib lath,preferably by placing the rib members at the corners of the top andsides of the channel and in addition to depress the top from the cornersso that the ribs provide edge guides, and absent any other structuralsupport member.

[0049] It is a further advantage to form the member out of woven wirelath also known as chicken wire, and preferably of the self furringform, absent any other structural support member, and in addition,preferably with edge guides applied to the corners of the top and sideof the channel.

[0050] It is a further advantage, where edge guides applied to cornersof the top and sides of the channel are cut-down to have shorter sideextensions.

[0051] In further embodiments, the invention resides in the constructionof relief form members using elongated welded wire assemblies havinglegs portions that are joined at a corner portion, the leg portionsbeing at a selected angle and the corner portion having at least onelengthwise extending tool guide wire. In a basic configuration weldedwire side members are positioned oppositely with the corner portionsdefining a corner of the relief form member and the legs defining asheight. The two assemblies are fastened together, hot melt glue being anexemplary fastening material. For best use a paper sheet is placed inthe space formed by the wire assemblies and fastened to them. The relieffrom is fastened to a wall and then plaster is applied to create a trimelement. In the simplest form a rectangular profile is created. The twoopposed wire assemblies can be adjusted to place the corners closer orfurther apart to create a desired width dimension for the rectangularprofile. A channel member of wire assembly can be placed between the twoside members to allow greater width selection. The height can beadjusted by selecting the angle between the leg portion; a greater angleresulting in more height and a smaller angle resulting in less height.By stacking, more complex profiles can be accomplished such as a twostep profile in which a smaller profile is set on top of a widerprofile.

[0052] In further embodiments, the invention resides in a prefabricatedrelief form member in which the wire assemblies are corner aids todefine the height and width of a relief form and the use of glue to holdthem together.

[0053] In further embodiments, the invention resides in a prefabricatedrelief form member having corner aids to define the height and width ofthe relief form and paper under the corner aids.

[0054] In further embodiments, corner aids define side corner aids andone or more additional corner aids which define channel corner aids.

[0055] In further embodiments a method of making relief form membersuses welded wire assemblies, in one particular, corner aids, by placingtwo side wire assemblies oppositely and fastening them together.

[0056] These and further embodiments of the invention are set out in theclaims as filed, amended and issued.

BRIEF DESCRIPTION OF THE DRAWINGS

[0057] For a further understanding of the objects and advantages of thepresent invention, reference should be had to the following detaileddescription, taken in conjunction with the accompanying drawings, inwhich like parts are given like reference numerals and wherein;

[0058]FIG. 1 is an exploded perspective view of prefabricated plasterrelief forms members aligned end to end in accordance with thisinvention.

[0059]FIG. 2 is a plan view of a section of expanded metal lath used asthe open work lattice material to make a preformed plaster relief formmember in accordance with this invention.

[0060]FIG. 3 is a perspective view of an alternative prefabricatedrelief form member having a paper backing.

[0061]FIG. 4 is a perspective view of an alternative prefabricatedplaster relief form member angled to fit around intersecting walls.

[0062]FIG. 5 is a perspective view of an alternative prefabricatedplaster relief form member angled to fit around door or window casings.

[0063]FIG. 6 is a perspective view of an alternative prefabricatedplaster relief form member having a prefabricated guide edge member inaccordance with this invention.

[0064]FIG. 7 is a cross section taken along viewing plane 7-7 of FIG. 6.

[0065]FIGS. 8a and 8 b are cross sections of two alternative plasterrelief form members in accordance with this invention.

[0066]FIG. 9 is an exploded perspective view of two plaster relief formmembers aligned end-to-end on a structural wall.

[0067]FIG. 10A is a perspective view of a previous art method ofattaching hand made plaster relief forms made of wood and wire screen.

[0068]FIG. 10B is a cross section of a previous art hand made plasterrelief form.

[0069]FIG. 10C is a cross section of a previous art hand plaster reliefform having separate guide edge members manually attached.

[0070]FIG. 11 is a perspective exploded diagrammatic view of a channelformed from welded-wire lath in accordance with this invention.

[0071]FIG. 12 is an end view of a preferred form of the invention shownin FIG. 11 in accordance with this invention.

[0072]FIG. 13 is a diagrammatic view of the invention as shown in FIGS.11 and 12 with edge guides added, in accordance with this invention.

[0073]FIG. 14 is a diagrammatic, exploded end view, of a form membermade from edge guides in accordance with this invention.

[0074]FIG. 15 is a diagrammatic end view of a form member made from riblath in accordance with this invention.

[0075]FIG. 16 is a diagrammatic perspective view of a form member madefrom woven wire also known as chicken wire, with edge guides attached inaccordance with the invention.

[0076]FIG. 17a is an end view of a type of corner bead.

[0077]FIG. 17b is a top view of the corner bead of FIG. 17a with theside extensions rotated into a plane.

[0078]FIG. 18 is a diagrammatic end view of a generic form member with acut-down edge guides in accordance with the invention.

[0079]FIG. 19 is a schematic end view of a corner aid used for reliefforms according to the invention.

[0080]FIG. 20 is a schematic end view of a modified corner aid used forrelief forms according to the invention.

[0081]FIG. 21 is a schematic end view of a relief form.

[0082]FIG. 22 is an end view of a fixture for modifying corner aid usedfor relief forms according to the invention.

[0083]FIG. 23 is a view of a fixture for making relief forms accordingto the invention.

[0084]FIG. 24 is a view of a relief form made and a bracket used formaking relief forms according to the invention.

[0085]FIG. 25 is an end schematic view of an architectural trim membermade according to the invention.

[0086]FIG. 26 is a channel corner aid for use in the invention.

[0087]FIG. 27 is a relief form according to the invention.

[0088]FIG. 28 is another relief form according to the invention.

[0089]FIG. 29 is another relief form according to the invention.

[0090]FIG. 30 is a sketch of a relief form according to the invention.

[0091]FIG. 31 is a sketch of a relief form of another relief formaccording to the invention.

[0092]FIG. 32 is a sketch of a relief form of another relief formaccording to the invention.

[0093]FIG. 33 is a sketch of a relief form of another relief formaccording to the invention.

[0094]FIG. 34 is a sketch of a profile of an architectural trim membermade from the relief form of FIG. 33.

[0095]FIG. 35 is a sketch of a relief form of another relief formaccording to the invention.

[0096]FIG. 36 is a sketch of a relief form of another relief formaccording to the invention.

[0097]FIG. 37 is a sketch of a profile of an architectural trim membermade from the relief form of FIG. 36.

[0098]FIG. 38 is a sketch of another relief form.

[0099]FIG. 39 is a profile of an architectural trim made form the reliefform of FIG. 38.

[0100]FIG. 40 is a sketch showing an architectural trim and the reliefform used to make it.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION

[0101] With reference to FIG. 1, there is shown an embodiment of theprefabricated plaster relief form member in accordance with thisinvention, generally referred to by the numeral 20. The member 20 isshown aligned end-to-end with similar members 20 a and 20 b. The member20 is formed from an open lattice material 22 such as 3.4 lb/sq. yd.diamond mesh expanded metal made by Western Metal Lath Company of SanLeandro, Calif. The lattice material 22 is bent on a tool such as asheet metal brake in a metal shop to form a longitudinal channel havinga protuberant contour 30 with a top surface 31, opposed sides 34, 36 atessentially right angles to surface 31, and opposed ends 38, 40. Thesides 34, 36 of lattice material 22 are bent to form flanges 42, 44extending at essentially right angles away from the respective sides 34,36 of the member 20. The flanges 42, 44 are configured to lie in thesame mounting plane 46 indicated by the arrows x, y. The mounting plane46 and flanges 42, 44 are essentially parallel to the length L of themember 20. The depth D of the member 20 is typically about 1{fraction(1/2)} inches, the width W typically about 6 to 12 inches and the lengthL typically 6 to 10 feet. The flanges 42, 44 extend a distance Ftypically about 1{fraction (1/2)} inches respectively from each side 34,35. The member 20 is configured so that each end 38, 40 can abutcontiguously at each end 38, 40 with adjacent identical members, asindicated by members 20 a and 20 b, to form a continuous relief bandwhen mounted on a prepared structural wall. The application and methodof use of prefabricated plaster relief bands is described below.

[0102] The members 20, 20 a, 20 b would typically be fabricated at aremote site, such as a metal shop or manufacturing plant by using toolswell known in the metal working trade.

[0103] A preferred manufacturing method for the prefabricated members 20is an automated means such as high speed punches and presses operatedwith appropriately configured molds to achieve a desire contour.Finished members 20 would then be shipped to a job site for installationby lower cost tradespeople.

[0104] With reference to FIG. 2, there is shown a detail of a typicallattice material 22. A preferred lattice 22 is typically formed ofgalvanized steel expanded to provide an hexagonal close packed array 48of cells 50 bounded by strands 52. The strands 52 are formed ofgalvanized sheet steel typically about 0.020 inches thick. The cells 50are elongated hexagons with major axis 54 about {fraction (11/16)} inchlong and minor axis 56 about {fraction (5/16)} inch wide. Alternatively,the lattice 22 may be formed of lighter or heavier expanded metal, suchas 1.75 lb/sq. yd. Or 2.5 lb/sq. yd. For smaller or larger preformedmembers. A suitable material is the galvanized steel diamond mesh of 3.4lb/sq. yd. Made by Western Metal Lath Co. La Mirada, Calif.\

[0105] With reference to FIG. 3, an alternative embodiment of aprefabricated plaster support member in accordance with this inventionis shown. A paper backed lattice material may be used to make a membergenerally indicated by numeral 60. An example of such a paper backedlattice material is “CEM-LATH K” made by Cemco, of Industry, Calif.“CEM-LATH K” is a 3.4 lb/sq. yd. Diamond mesh metal lath 62 backed withasphalt saturated “Kraft” paper 64 which may be used to form a plastersupport member 60 in accordance with this invention. The paper backing64 may be used to limit the amount of plaster which is needed to coverthe member 60 after the member 60 is applied to a prepared structuralwall (not shown).

[0106] The paper 64 extends a suitable distance such as 1½ to 2 inchesbeyond the flanges 42, 44 and ends 38, 40 of the metal lath 62. Thepaper 64 extension provides an overlap with adjacent paper backedmembers (not shown), when aligned end to end, to ensure a continuousmoisture barrier which may be required by local or state building codes.

[0107] It is contemplated that the paper 64 may be applied to the backof the lath 62 before forming the member 60. Application of the paper 64to the back of the lath 62 may be made by adhesive means such as a hotglue (not shown) between the paper 64 and the lath 62. The paper 64 andthe lath 62 may then be positioned between an upper mold and a lowermold having a desired shape (not shown). Application of sufficientpressure between the upper mold and lower mold will cause the lath 62and paper 64 combination to be shaped into the desired member 60.

[0108] Other preformed shapes for prefabricated plaster form members inaccordance with this invention are contemplated. With reference to FIG.4 there is shown an embodiment of a prefabricated angled member 80. Theangled member 80 provides a means to fit a continuous relief band aroundthe corner of a building (not shown) without cutting and fittingstraight members. The member 80 is made from open work lattice materialas described above. The member 80 includes a first portion 82 and asecond portion 84 joined at a common edge 86. The portions 82 and 84 maybe joined by suitable means such as spot-welding, hot gluing or wiretying, as is well known in the trade. The portion 82 and portion 84 areindicated at right angles to each other, but can be any desired angle toaccommodate intersecting structural walls at other than 90 degreeangles. The portions 82, 84 are configured to have similar protuberantcross sections and protrude in a direction normal to the respectiveintersecting walls. The portions 82, 84 have respective lengths L1 andL2 measured from the common edge 86 to respective ends 38, 40. Theportions 82 and 84 have top surfaces 85 a, 85 b intersecting at edge 86.The portions 82 and 84 have respective sides 88 a, 88 b, and 90 a, 90 bbetween the respective walls and respective top surfaces 85 a, 85 b.Mounting flanges 92 a, 92 b and 94 a, 94 b project outward fromrespective sides 88 a, 88 b, and 90 a, 90 b. Flanges 92 a, 92 b and 94a, 94 b are configured to lie in intersecting mounting planes and areadapted to fit parallel to the respective adjacent intersectingstructural walls.

[0109] The member 80 is attached to the studs of a prepared structuralwall by means of nails or staples driven through the respective flanges92 a-94 b. Self-tapping sheet metal screws are typically used to attachthe flanges 92 a-94 b to metal studs. Sharp pointed “Streaker”self-tapping sheet metal screws available from Pacific Steel and Supply,San Leandro, Calif., may be used for light gauge metal studs.

[0110] The ends 38 and 40 of member 80 are configured as before to abutor overlap contiguously with respective ends of prefabricated plasterform members having the same cross section as the member 80. One suchabutting relationship with a plaster form member 20 having the samecross section as member 80 is indicated by the exploded view of member20 shown in FIG. 4.

[0111] It is often desired to fit the perimeter of door or windowopenings with decorative plaster elements. With reference to FIG. 5,another embodiment of an angled prefabricated plaster form member inaccordance with this invention is shown and generally indicated bynumeral 100. In one embodiment, the member 100 is made from expandedmetal lath as before described. A first portion 102 is joined with asecond portion 104 at a common edge 106. Portion 102 includes a sheet ofexpanded metal lath bent for form spaced apart sides 110 a and 110 b, atop surface 114 and respective mounting flanges 116 a and 116 b. Portion104 includes a sheet of expanded metal lath bent to form spaced apartsides 118 a and 118 b, a top surface 115 and respective mounting flanges120 a and 120 b. Portions 102 and 104 are configured to be symmetricalabout the common edge 106. The mounting flanges 116 a, 116 b, 120 a and120 b lie in the same mounting plane indicated by arrows x, y. Flanges116 a, 116 b and 120 a, 120 b are connected to the respective topsurfaces 114 and 118 by the depending sides 110 a, 110 b and 118 a, 118b. The top surfaces 114, 115 lie in the same plane and are parallel tothe mounting flanges 116 a, 116 b, 120 a, 120 b.

Alternative Preformed Plaster Relief Form Member

[0112] The previous art method of attaching separate guide edge membersto the hand formed plaster relief forms incurs extra handling andadditional cost due to high rate labor charges. With reference to FIG.6, there is illustrated a perspective view of a portion of analternative preformed plaster relief form in accordance with thisinvention, and generally referred to as numeral 150. As before describedwith reference to FIG. 1, wherein similar reference numerals are used todesignate similar elements, the member 150 is formed of an open worklattice material 22. A preferred lattice material is a diamond meshexpanded metal such as 3.4 lb/sq. yd galvanized metal lath made by CEMCOof Covina Lane, Industry, Calif. The lattice material 22 of member 150is preformed to include a top surface 31 having opposed ends 38, 40. Thetop surface 31 has a bending line along the surface 31. The bending lineis normal to the opposed ends and defines an edge 33. The latticematerial 22 is bent along the edge 33 to define a side 34 extendingdownward from the top surface 31. The side 34 extends downward asuitable distance from the top surface 31, to a second bending line 35,for example, 1½ inches. The lattice material 22 is bent along the secondbending line 35, to form a mounting flange 42 extending laterallyoutward from the side 34 of the member 150 to a suitable distance F,e.g. 1½ inches. A similar bending line, edge, side and flange (notshown) may be formed in a symmetrical relationship to the side 34 asbefore described and shown in FIG. 1.

[0113] A prefabricated guide edge member 160 is shown in explodedrelationship to the member 150 as member 160 for clarity. Guide edgemember 160 is attached at a plurality of points 162 along a first edge164 to the top surface 31 of the member 150. The edge member 160 isattached at a second plurality of points 166 to the side 34 of member150. The method of attachment may be spot welding, or bonding with anadhesive such as hot glue. A preferred guide edge member 160 is thestandard Bullnose regular cover nose wire having standard 1{fraction(1/2)} inch legs made by Stockton Products, Covina, Calif. The guidemember 160 includes a guide edge 168 spaced apart from, and parallel to,the intersection of the top surface 31 and the side 34. The guide edge168 is spaced apart a suitable distance, e.g. {fraction (5/8)} inch fromthe top surface 31 of the member 150. The guide edge 168 provides anedge to guide a tool, such as a trowel, while applying plaster to themember 150, in such a manner that a uniform plaster coating thickness iseasily achieved on the top surface 31. The guide member 160 includes aplurality of wire support members 170 and 172 connecting the guide edge168 and the respective top 31 and side 34 of the member 150. A similarguide edge 174 spaced apart form the side 34 by a suitable distance,e.g. {fraction (5/8)} inch provides an edge to guide a tool along themember 150 to achieve a uniform plaster coating thickness along the side34.

[0114] The exploded view of the member 160 illustrates correspondingattachment points 162 and 166, the connecting wires 170′ and 172′ andthe guide edge 168′.

[0115] With reference to FIG. 7, there is shown in cross section alongthe viewing plane indicated by 7-7 of FIG. 6, the contour of the edgeguide member 160 attached to the top 31 and the side 34 of the member150 at attachment points 162, 166 respectively. The top guide edge 168and side guide edge 174 are shown as wires attached to the connectionwires 170 and 172 and spaced apart from the top surface 31 and the side34 by a suitable distance, typically {fraction (5/8)} inch.

Alternative Cross Sections for Prefabricated Plaster Relief Forms

[0116] With reference to FIGS. 8a and 8 b there are shown alternativecross sections for prefabricated plaster relief form members inaccordance with this invention. FIG. 8a illustrates a member 200 havingopposed sides 202, 203 configured in a stair-stepped shape to providetwo layers of relief.

[0117]FIG. 8b illustrates a cross section of a prefabricated plasterrelief form member 204 having a stair-stepped aspect with four corneredges 206, 208, 210, 212. Each edge 206-212 has a respective guide edgemembers 214, 216, 218, 220. Each guide edge member 214-220 provides atop and a side guide edge 214 a, b-220 a,b spaced apart from therespective corner edges 206-212 by a suitable distance, e.g. {fraction(5/8)} inch laterally outward and vertically upward.

[0118] With reference to FIG. 9, the use of the prefabricated plasterrelief form is herein described. In use, a structural wall is preparedhaving a plurality of studs 180 spaced a suitable distance apart andmounted vertically along a foundation 182. A layer of asphalted “Kraft”paper 184 for a moisture barrier is applied to the studs 180. A firstlayer of wire mesh or screen 186 (commonly called chicken wire) is thenattached to the wall over the paper 184. A line is defined along thewall wherein the desired decorative architectural structure was to beplaced. A plurality of prefabricated plaster relief form members 200 isaligned end to end along the line and attached to the wall by means ofnails or staples 186 driven through respective mounting flanges 42, 44into the studs 180. The light weight but substantially rigid latticematerial 22 and uniformity of shape provided by the preformed members200 would make the task of creating a uniform, continuous relief bandextremely easy. With reference again to the detail of FIG. 2, the array48 of open cells 50 of the lattice material 22 provides ready access forthe application of plaster to envelop the strands 52 and bond firmlywith the lattice 22.

[0119] The prefabricated guide edges 160 and 190 of the preformedplaster relief form 200 provide guides for guiding a tool to applyplaster to a uniform thickness along the relief form members 200.

[0120] One method of applying a cementitious coating is the well knownthree step process. A first coat of cementitious material, typicallyplaster, called a scratch coat, would be applied, either by hand trowelor by spraying from a nozzle connected to a gun feeder, hopper/mixer andpumps as is well known to those skilled in the art.

[0121] One preferred formulation for the scratch coat is set forth inTable 1. It is within the teachings of this patent to use any othersuitable cementitious material to form the coating for the wall andprefabricated plaster form 20. TABLE 1 1 part Colton Portland Cementtype II 3 parts common coarse sand 5 to 8 gallons of water per sack ofcement, depending on the water content of the sand

[0122] The scratch coat covers the wall and the sides and top surface ofthe form members 20 to a uniform depth of about {fraction (3/8)} inch.The scratch coat is cured for a suitable time, such as 24 to 48 hours,according to the State of California Uniform Building Code 1988 Editionpage 4706, herein incorporated by reference.

[0123] A second coat of plaster about ¼ to ¾ inches, with a preferredthickness or {fraction (3/8)} inch, called the brown coat, is appliedsimilarly to the wall and plaster forms 20. The brown coat is cured fora suitable time such as 7 to 14 days minimum. A suitable formulation forthe brown coat is the same as Table 1, with the addition of a 3 to 5shovelsful of sand per sack of cement.

[0124] A final plaster coast incorporating the desired color is appliedsimilarly to a depth of about {fraction (1/16)} to {fraction (1/8)}inch. The formulation for the color coat is typically a mechanicallyblended compound of portland cement, hydrated lime and inert aggregates(16/20 or 20/30 sand), such as that supplied by La Habra Stucco,Anaheim, Calif. Material standards preferably meet Federal SpecificationSS-L-351, Type F for hydrated lime, and Type 1 ASTM C150-56: FederalSpecification SS-C-192B, for white portland cement.

Further Embodiments

[0125] A further embodiment of the invention is illustrated in FIG. 11.This embodiment takes advantage of an existing product used inconstruction. In this embodiment the relief form member 200 is made of ametal mesh 202 of the type known as welded wire, preferably in the formof 2“X2” mesh, using 16 or 17 gauge wire. Paper backing comes attachedto the wire mesh when it is made and sold as by manufacturers forplastering purposes. In this form it is referred to in the industry aswelded wire lath. An example is that used in a product sold asStucco-Rite by K-Lath of Fontana, Calif. The attached Appendix A is acopy of K-Lath's catalogue A465,09200/KLC, Bayline 5409 showing variousforms of lath.

[0126] Referring to FIG. 11, the welded wire mesh 202 is formed asdescribed above into a channel shape having mounting flanges 204, sides206 and a top 208. The mounting flanges 204 are preferably ½ inch to 1½inch extending away from the sides 206. The height of the side 206 isdictated by the desired design dimension, 1½ inches being exemplary.Paper backing 210 follows the form of the channel and is attached to thewire mesh 202 by an interweaving as known in its preparation as lath.The width of the top 208 is also a design choice, 6 to 12 inches beingexemplary. The relief form member can be of any selected length for theuse, and can be preformed in exemplary lengths such as 6 to 10 feet.

[0127] This embodiment has a further alternative in which a productknown as double wire mesh is used. The double wire mesh material is usedin a lath product sold as Stucco Rite Double Wire by K-Lath of Fontana,Calif., as described in the catalogue identified above. The double wiresare provided at selected intervals. The double wire form provides anailing space between the double wires to catch the nail head andprevent movement during installation.

[0128] When forming the channel shape using the welded wire mesh, thebends can be anywhere, but referring to FIG. 12, it is preferable tohave lengthwise extending wires 212 at the bends or corners, as well ashaving a lengthwise extending wire proximate the outer termination 214.Since the welded wire mesh comes in specified dimensions, whether singleor double wire, to place the lengthwise wires at the bends or cornersdictates the dimensions of the channel. This structure gives additionalrigidity which aids in installation. The paper backing 210 is shownattached to the wire mesh 202 by interweaving as is known in themanufacture of welded wire lath. A second layer of paper 215 is commonlyemployed having an asphaltic or other waterproofing component.

[0129] The foregoing alternatives using welded wire mesh can be used asdescribed, or with corner beads also known as edge metal or edge guidesas previously described and shown diagrammatically in cross-section inFIG. 13. Corner beads are sold by various manufacturers such as CEMCO ofIndustry, Calif. Appendix B is a copy of CEMCO's catalogue of Metal Lathand Accessories. Without the corner beads, certain architecture stylessuch as Spanish or mission finish are facilitated. With the corner beadsor edge guides, a smooth finish is achievable. The corner beads can beattached by any suitable means, such as by hot glue. Referring to FIG.13 the wire mesh 202 has corner beads 216 attached at the corners of thetop 208 and sides 206. Paper backing 210 is shown.

[0130] Another alternative construction of the invention uses onlycorner bead members joined together to form the channel. This is showndiagrammatically in FIG. 14 in which corner beads 220 and 222 form theflanges 224 and along with corner beads 226 and 228, form the sides 230and the corner beads 226 and 228 form the top 232. To form the top 232,corner beads 226 and 228 may overlap as shown at P although they canabut. The four corner beads are joined along their length by any desiredmeans such as wire ties, welding or hot glue. Also, paper backing 234 isapplied, held in place such as by hot glue, and can include an asphaltcoated layer. The corner beads can be any known type, such as bullnose,or straight wire edge guides.

[0131] Referring to FIG. 15, in another alternative the channel isconstructed by using a product known as rib lath. Rib lath is a knownproduct, similar to the expanded metal described above, but havingparallel ribs of solid, unexpanded portions extending lengthwise betweenareas of expanded metal. The rib lath is shown in the CEMCO catalogue.The ribs may be about ⅜″ wide and spaced apart about 1⅛ inch with threeexpanded portions between them. Referring to FIG. 15, the rib lath 238has the ribs 240 and the expanded metal portions 242 between the ribs.The rib lath 238 is formed into a channel shape as showndiagrammatically having raised corners where the sides and top meet withribs 240 at the corners to serve as edge guides. In FIG. 15, the longerlines 240 represent the ribs and the shorter lines and spaces 242represent the expanded metal portions. The rib lath structure ispreferably also used with paper backing as described above. In this formthe corner bead or edge guide is built into the channel form itself. Thesides of the channel could be convergent from top to flange to providean edge guide for the sides, or the sides could be bent, like the top sothat the corner protrudes to provide an edge guide for the sides.

[0132] Referring to FIG. 16, in another alternative series of structuresany of the foregoing shapes can be formed using woven wire also known aschicken wire for the basic channel shape. This wire is referred to asStucco Netting in the K-Lath Catalogue. It is preferably augmented withpaper backing and as desired with corner beads as described above. Theself-furring form is preferred to keep a space between the wire and thepaper backing. The woven wire is formed into a channel 250, with flanges252, sides 254 and top 256. Corner beads 258 are attached as well aspaper backing 260.

[0133] Corner beads are commonly made with lengthwise wires at the apexto form a bullnose or straight shape and undulating and straight wirescombined to provide an extension away from the apex. In the CEMCOcatalogue this is shown on page 8 as CEMCORNER. FIGS. 17a and 17 b showsthis structure with wires 270, 272 and 274 defining an apex, and theremainder of the structure of undulating wires 276 and straight wires278 forming side extensions away from the apex. In the presentinvention, referring to FIGS. 17a and 17 b, this type of corner bead canbe used as shown in the CEMCO catalogue, but in a further embodiment theside extensions can be cut away to make it smaller. Selected places forlengthwise cutting away are shown at A-A, B-B, C-C and D-D. The formcreated by the cutting away along line D is shown in FIG. 18.

[0134] In all of these alternative constructions, no underlyingstructural support member is used. In particular any wood boards areabsent.

[0135] In all of these further embodiments, the shape of the channel canbe made in the stepped form as shown in FIGS. 8a and 8 b except that thechannel is made of materials as described in these further embodimentsand absent any additional underlying support such as wood boards.

Still Further Embodiments

[0136] It can be fully appreciated that as with all construction it is aconstant creative goal to reduce cost while maintaining or improvingfunctional qualities. Such a goal has been demonstrated from theforegoing embodiments and explanations. Yet further embodiments that goeven further toward economic construction of architectural trim elementshave been invented. For clarity it is preferred to refer to thestructure after it has been installed and plastered as an architecturaltrim and to refer to the structure prior to its installation andplastering as a relief form. That is, a relief form is constructed sothat it can then be used on a building to create an architectural trim.

[0137] In the broadest aspect the further embodiments of the inventionuses as the structural elements, connected wire assembly members thatare prepared in lengths and configured to provide the resultant reliefforms by being fastened together. One aspect of the connected wireassembly members are welded wire assembly members. Another aspect istwisted wire assembly members. In any case the connected wire assemblymember must have sufficient strength. This is largely controlled by thewire size. It is considered that for welded wire assembly members arange from 20 gauge to 16 gauge wire is acceptable. Heavier than 16gauge is unnecessary and lighter than 20 gauge is insufficiently rigid.The preferred range is 18 gauge to 16 gauge and the best is 17 gauge.Each connected wire assembly member has two portions at a selected angleto each other portion joined at a corner. The corner has at least oneaid wire running lengthwise. In the case of twisted wire assemblymembers the at least one tool guide wire has to be attached by anadditional means such as welding. As will be seen one leg portiondefines the height dimension.

[0138] In a preferred aspect the further embodiments use commerciallyavailable corner aid product as the structural elements. Corner aids arewell known construction materials that are applied to corners tofacilitate the application of plaster. They come in 10 foot lengths aswell as other lengths They are called by various generic names such ascorner reinforcement, corner aid, and corner. They are made by a numberof companies and the manufacturers make them in somewhat differentshapes and configurations. CEMCO of Industry Calif. calls themCEMCORNER. Jaenson Wire Company of Fontana Calif. calls them BestCorners. K-Lath, of Fontana Calif. a division of Georgetown Wire Companycalls them KwikComer, KwikFlange and KwikRound.

[0139] By using corner aids to build relief forms for architecturaltrim, cost is reduced; but in addition construction of a variety ofarchitectural trim shapes is facilitated. Also the survivability of thetrim is enhanced. The invention resides in the assembly of parts andmethods of assembly which includes the new use of corner aids as well asin the process of creating the relief form and, upon, installation andapplication of plaster, the process of creating architectural trimmembers constructed using those parts.

[0140] Corner aids come in various configurations. They are made ofwire, either 16 or 17 gauge usually galvanized being very common andpreferred for the present invention, the 17 gauge being most preferred.Since corner aids are made by several manufacturers it is the intent forpurposes of this description to include all corner aids that are made ofwire welded together and having legs at an angle and a corner aid atleast one longitudinal wire for guiding a tool. They come as “sharp”having a single longitudinal wire at the apex or “bullnose” having aplurality of longitudinal wires, three or four being common, spacedaround a rounded apex. They can have a single outside wire on each legor double outside wires. The body of the corner aid is constructed ofundulating wires such as two opposed waveforms for each leg of thecorner aid and one forming the top. All the parts are welded together.

[0141]FIG. 19 shows an end view, also referred to as a profile, of acommercially available bullnose corner aid 300. The bullnose form isgenerally preferred for use in the present invention as is the doublenailing wire form. However the right angle form or any of the otherforms may also be used. The line 302 in FIG. 19 represents an end viewof the undulating welded-together wires that extend the length of thecorner aid 300. For purposes of this description it is useful to definethe corner aid 300 as having leg portions 304 a and 304 b, corner ornose portion 306 and ends 308 a and 308 b. The dots 310 a, 310 b, and310 c represent longitudinal wires that define the corner of a bullnosetype corner aid 300, in this figure, corner portion 306. These wireshelp to guide a plaster's tool and are referred to herein as tool guidewires. The dots 312 a and 312 b represent intermediate longitudinalwires welded to the inside of the undulating wires. The dot pairs 314 aand 314 b represent the longitudinal double nailing wires near the ends308 a and 308 b. The wires 310 a, band c and 312 a and band 314 a andbare all parallel and are welded to the undulating wires 302 and extendlongitudinally the length of the corner aid 300. The bullnose corner aid300 has an opening of about 3 inches and the legs 304 a and 304 b are atan angle of about 90 degrees as shown in FIG. 19.

[0142] With reference to FIGS. 20-27 the process for constructing reliefforms for architectural trim members using commercially available corneraid will be explained.

[0143] The majority of relief forms of the invention are assembled fromtwo corner aids either alone or in combination with other corner aidsthat may be adjusted in a specified way to provide the basic parts forthe relief form. The two corner aids referred to as side corner aidsdefine the corners of the relief form and ultimately the profile of thearchitectural trim element. An exemplary adjustment is seen in FIG. 20in which the dimension of the opening of a corner aid 300 has beenreduced to about 2⅛ in. by reducing the angle between the leg portions304 a and 304 b. This adjustment will be applied in a preferredembodiment to side corner aids although it will be appreciated that sidecorner aids may be used without adjustment. This will be described ingreater detail below.

[0144] In FIG. 21 there is shown an end view of a particular relief formmember after it has been made. It is constructed from two pieces of 10foot lengths or other length of bullnose corner aid 300 whose openingshave been reduced as shown in FIG. 20. The two lengths of corner aid 300are placed so that leg portions 304 a approximately approach near ormeet centrally at “A” and leg portions 304 b extend downwardly (it isnot intended that any distinction in the construction be implied betweenleg portion 304 a and leg portion 304 b, they are interchangeable). Apaper insert 316 extends inside the space formed by the two corner aids300. The purpose of the paper is for backing the first coat of appliedplaster. The paper can be perforated to allow plaster keying and waterto drain.

[0145] A suitable paper is Ratan Red Rosin Sized Sheathing 41 b/Standardavailable from Salinas Valley Wax Paper Company in Salinas, Calif.Another suitable paper is a single-ply, heavyweight, hard-sized kraftpaper called Fortifiber Utility Paper from Fortifiber Building ProductsSystems of Reno Nev. Also it has been found that recycled paper ispreferred because it has greater water absorbency which is beneficial toabsorb water from the plaster.

[0146] As shown in FIG. 21 side corner aids 302 a and 302 b have beenslightly adjusted in angle as described above. Reducing the angleprovides a better profile for application of plaster. Specifically, asufficient space is established for the application of plaster with theadjustment. With sufficient demand it is contemplated that the corneraid could be acquired from manufactures with the desired preferredangle. Of course instead of corner aid as connected wire assembly can beused that is specifically designed and manufactured for the presentapplication. The three parts, the two corner aids 300 and the paperinsert 316 are held together by glue. At spaced intervals along thelength of the relief from glue deposit 318 is deposited in the form ofhot melt glue. Glue deposit 318, encapsulates a portion of the corneraids 300 and sticks to the paper insert 316. Also glue deposits 320 alsoat spaced intervals along the length of the relief form hold the paperinsert 316 to the leg portions 304 b.

[0147] Construction of the relief form is now described with referenceto FIGS. 22, 23 and 24

[0148] The adjustment of the angle of the corner aid 300 is accomplishedin a fixture 320 as shown in FIG. 22. The fixture 322 has a horizontalleg 324 and a hinged leg 326. The horizontal leg 324 and hinged leg 326are attached by a hinge 328 so that hinged leg 326 can move in an arc“B”. On the inside of the horizontal leg 324 are spaced apart fingers330 and threaded through the end of the hinged leg 326 is an adjustingassembly 332 that adjustably limits the movement of the hinged leg 326.The fixture is long enough to operate on a ten foot length of corneraid, so the fingers 330 will be spaced along the length of thehorizontal leg 322 and there may be more than one of the adjustingassemblies 332 along the length of the hinged leg 326. The corner aid300 is placed in the fixture as shown in FIG. 21 and the hinged leg 326of the fixture is pushed closed until the adjusting assembly 332 stopsit so that the leg portions 304 a and 304 b of the corner aid 300 areadjusted to the desired angle.

[0149] With the corner aids 300 prepared an assembly fixture 340 isprovided which is shown in FIG. 23. The assembly fixture 340 has a table342 which can be a series of spaced apart frames 344. Laid onto thetable 342 is a core piece 346 that has a rectangular cross-section.

[0150] The core piece 346 has a selected height “H” and width “W” (seeFIG. 24) For the relief form member shown in FIGS. 21 and 24 thedimensions are about H=1 in. and about W=3¼ in. It can be appreciatedthat in the prior art method a 2×4 stud or other selected wood plankswere used (such as a 2×6), being nailed to the wall. As will beappreciated using the present invention, the relief form and the trimresulting from its use can be made in a wide range of dimensions for itsprofile. Also as will be seen numerous special relief forms can beconstructed, not only single rectangular profiles, but also steppedprofiles and cornice shapes, to name a few. Therefore an architect canspecify the shape and dimensions of the architectural trim member tosuit and the assembly fixture can be made to produce relief forms thatwill result in the specified trim member. The approximate size of thethe relief form shown in FIGS. 21 and 24 is about 5 in. wide and about3½ in. high. But, as indicated by the arrow “A” in FIG. 21. the widthdimension can be varied as long as good fastenings are possible to keepthe side corner aids 300 rigidly fastened to each other. In the case ofthe use of hot melt glue spots 318, the side corner aids 300 can beslightly overlapped or even spaced apart somewhat so long as a good gluespot can be applied.

[0151] The assembly fixture 340 also includes a set of alignmentbrackets 348 which have a height leg 350 and a width leg 352 as shown inFIGS. 23 and 24.

[0152] Referring to FIG. 24 the construction of the relief is described.A length of appropriate paper 354 is selected and cut to size. The paper354 is folded onto the core piece 346 The paper has a length consistentwith the length of the relief from, 10 feet being typical; it has awidth sufficient to allow it to be loosely draped over the core piece346 and to extend to or near the bottom of the core piece 346. Next, thepreviously prepared corner aids 300 are placed on top of the paper 354to define parallel opposed elongate side corner aids.

[0153] Then, the alignment brackets 348 are set on top of the sidecorner aids 300, spaced apart along the length of the core piece 354(see FIG. 23). The alignment brackets 348 will adjust the placement ofthe side corner aids 300 so that they are aligned along the length ofthe core piece 354 and also with each other, setting a constant width Das determined by the dimension D across the inside of the legs 350 ofthe alignment brackets 348 and a constant height E along the length. Forbest results, the corner aids 300 are manually urged apart so that theywill contact the legs 350 of the alignment brackets 348. Now it isconvenient to define the legs 304 a as upper width legs whose placementand length will set the width of the relief form and legs 304 b asheight legs that will set the height of the relief form.

[0154] Next using a hot glue application machine 356 (FIGS. 23 and 24),hot glue is spot applied along the length of the relief form at selectedintervals. The hot glue is applied so as to create a glue spot 358 thatencapsulates adjacent or overlapping portions of each of the legs 304 aand to also adheres to the paper 354. The paper 354 should also be spotglued to create glue spots 360 at the leg portions 302 a and 302 b ofthe corner aid 300 that define the sides of the relief form so as toprovide backing for the plaster when it is later applied.

[0155] The result is a structurally firm relief form that can then beattached to a building structure with nails and subsequently plastered,such as with standard three layer plaster procedure (a scratch cost, abrown coat and a color coat) as is well known in the art.

[0156] Referring to FIG. 25, the next step in creating a trim is to nailor in any other way, fasten, the relief form 300 to a wall 315. Itshould be appreciated that the nailing or other fixing to the wall isnot for strength purposes, but simply to position the relief form forplastering. It is the plastering that provides adequate strength. If itis new construction the relief form should be attached to the wallbefore any plaster is applied to the wall. If it is a later application,then the wall can be prepared by removing plaster from the wall adjacentto the area where the relief form will be installed; or the relief formcan be simply installed over existing plaster finish.

[0157] As can be seen in FIG. 25, after the relief form 300 is nailedwith nails 362 (the nails can be placed in any or varied places in therelief form so long as the nails heads hold it in place) to the wall.The nails 362 will pass through the wall lath 368 into wood structure370. Then the plaster is applied. As shown in FIG. 24, to completeinstallation of the relief form and create an architectural trim, thecommon three step plastering process is shown, the scratch coat 372, thebrown coat 374 and the color or finish coat 376 which is merged with theplaster 378 on the wall. The application of plaster is known andtherefore it is not necessary to explain it in detail. Other plasteringprocedures can be used, for example the diamond wall method.

[0158] Numerous other configurations of relief forms are available usingthe basic concept of the invention as modified in application. Some ofthese are now described.

[0159] Referring to FIGS. 26 and 27, an alternative for the relief form380 is shown in which a third corner aid 382 is used. This configurationcan also be used for wider widths and allows greater adjustability forselecting a width. Note that FIGS. 25 and 26 show corner aids that havefour linear wires at the nose (also called the corner) while theprevious description shows three linear wires at the nose; this ismerely illustrative of the interchangeability of corner aidconstructions in the present invention. To prepare the side corner aids300, the same procedure as described above is used. The additionalcorner aid 382, called a channel corner aid to distinguish it from theside corner aids 300, is prepared by flattening a corner aid to a gentlecurve so that it extends into the space in the side corner aids 300.Paper 384 is in place inside the channel formed by the corner aids. Gluespots 386 a and 386 b are placed at selectively spaced intervals alongthe length of the relief form to encapsulate the side corner aids 300,the channel corner aid 382 and to adhere to the paper 384. The paper 384is also glued as described above at 388 a and 388 b. The degree offlattening of the channel corner aid, to be either flat or bowed isselected to allow good interfitting with the side corner aids and togive good rigidity. This assembly allows the width of the relief form tobe selected by either or both selecting a wider channel corner aid orselecting more or less overlap of the channel corner aid and the sidecorner aids. Also, although use of corner aid to create the channelcorner aid is convenient, that member can more broadly be called achannel element and can be made of any connected wire assembly ofsufficient strength; its width being selected to suite the desired widthof the relief form and the amount of overlap desired.

[0160] The relief form 380 shown in FIG. 26 is made according to thesame method described above except that after the paper 384 is placed onthe core 346, the channel corner aid 382 is placed over it; then theside corner aids 300 are put in place and the alignment brackets 350 areput in place to finalize the shape and then the glue spots are applied.Of course both the core and the alignment brackets are made withselected dimensions to provide the desired size of the relief form.

[0161] Referring to FIG. 28 another alternative relief form 390 is shownalthough it is in generally similar to that shown in FIG. 27 in that ituses two side corner aids and a single channel corner aid. In this formthe side corner aids 300 are separated by a greater distance than asshown in FIG. 26 and the channel corner aid 392 is flatter. Paper 394 isin place below the channel corner aid 392. Glue spots 396 a and 396 b atselected spaced apart locations encapsulate the side corner aids 300 andthe channel corner aid 392 and adhere to the paper 394. Also glue spots398 a and 398 b are applied. This relief form is made in the sameprocedure as described above; but the alignment brackets and the corepiece used are wider to define and control the greater spacing betweenthe side corner aids 300; and the paper has to be wider. The size of therelief form of FIG. 27 is, for example, nominally 6⅞ in. wide.

[0162]FIG. 29 shows a relief form similar in height dimension to thatshown in FIG. 28 except that in this form two channel corner aids 400and 402 are used. Glue spots 404 a and 404 b are placed at selectedintervals as are glue spots 406 a and 406 b. Paper 410 is similarly inplace. The method of making this version is generally the same exceptthat the core piece, the paper and the alignment brackets have to besized to provide the desired dimensions, as is the case for all of thefollowing versions. This provides greater strength and a longer range ofsize availability.

[0163] It can be appreciated that adjustment of the width of the reliefforms is allowed by use of wider or thinner alignment brackets so longas it is possible to apply the glue spots and sufficient rigidity ismaintained. For example in the case of the relief form of FIG. 29, theoverlapping channel corner aids 400 and 402 can be placed to be more orless overlapped in order to shorten or lengthen the overall width; andthe side corner aids can be placed closer or further apart.

[0164] Additional relief from versions are now described with referenceto schematic illustrations. In each case the fixtures for spacing areselected and the channel corner aids are opened to be bowed or straightas desired. Glue spots are applied as appropriate.

[0165]FIG. 30 shows a relief form version similar to the one shown inFIG. 29 except that a third channel corner aid 412 is employed toprovide the added width. Paper 414 is placed below the corner aids Theouter two channel corner aids 404 a and 404 b overlap the centralchannel corner aid 412, but do not necessarily overlap each other. Gluespots are applied in selected places along the width.

[0166]FIG. 31 shows an added strength version useful in wider versions.In the added strength version an additional central channel corner aid416 is used but it is placed with the bowing opposite, that is, bowedupwardly.

[0167]FIG. 32 shows another added strength version, particularly usefulfor wide configurations, in which an additional channel corner aid 418is placed below the paper. It is spot glued to the paper 414 from belowby turning the relief form over. The bowing can be configured to provideadded rigidity by giving it a truss shape bowed downwardly as shown inthe figure. This configuration is particularly desirable in very wideversions, for example having an overall nominal width of 13 in. or more.Even more strength can be achieved by adding the central channel corneraid 416 as shown in FIG. 31. Preferably the corner aid 418 below thepaper is curved enough to approach contact with the wall on which itwill be mounted to prevent collapsing or bending inward as plaster isapplied.

[0168] Combined versions are also possible. For example as shown in FIG.33 a smaller version 420 like the one shown in FIG. 28 is mounted on topof a larger version 422 like the one shown in FIG. 29 to give a two stepstacked configuration 424. The two versions are hot spot glued together.After application of plaster, this configuration will look like 426 asseen in FIG. 34.

[0169] A very thin section version 428 is shown in FIG. 35 in which theside corner aids 300 are substantially overlapped, with paper 430 below.The process is the same as described above with an appropriatelydimensioned core (a core can be rotated 90 degrees), alignment bracketsand paper.

[0170]FIG. 36 shows a stacked combination of the version 428 of FIG. 35mounted by spot gluing on top of a version 432 similar to theconstruction shown in FIG. 29 (note the reduced overlap of channelcorner aids). FIG. 37 shows the profile of the completed two steparchitectural trim 434 made from the relief form of FIG. 36.

[0171]FIGS. 38 and 39 show respectively an offset two step stackedrelief form 436 and the profile of the resulting architectural trim 438.

[0172]FIG. 40 shows a two step stacked configuration of relief forms, asmaller relief form 440 stacked on a larger relief form 442 and in whichan auxiliary piece of cut down corner aid 444 is attached to the stackedrelief forms 440 and 442. The resulting architectural trim 446 can beused as a trim feature or as a cornice or as a pot shelf under a window.

[0173] The fastenings to be used in this invention can be selected;including for example weldments and the hot melt glue as describedabove.

[0174] The method of the invention includes starting with a desiredarchitectural trim configuration such a rectangular one step or twostepped profile or a more complicated cornice shape, for example andcalculating backward, that is, conceiving the configuration of connectedwire assemblies, channel elements, paper, fastenings that are requiredto provide the structural body needed to realize the trim member, makingthe prefabricated relief form as described above, and then after theprefabricated relief form has been applied to a wall, applying theplaster to realize the final shape.

[0175] As the foregoing descriptions of various possible configurationsand combinations of relief forms illustrates, numerous shapes can berealized for resulting architectural trim by variations in constructionof the relief form. It is the preferred method that, aside from thestandard rectangular single and symmetrically two step stacked shapes;any desired shape can be realized by starting from the desired endresult architectural trim. Then, the corner aid configuration is devisedto provide a relief form that will allow plastering to give the desiredend result. While this generally comprises the use of complete corneraids, a corner aid can be cut or bent to fit odd shapes. As noted,broadly, connected wire assemblies can be constructed and used, whileone such assembly, commercially available corner aids are a preferredstructure.

[0176] While the foregoing detailed description has described theembodiments of the plaster relief form member in accordance with thisinvention, it is to be understood that the above description isillustrative only and not limiting of the disclosed invention. Thus theinvention is to be limited only by the claims as set forth below.

1. A prefabricated relief form member for receiving and retaining acementitious coating when the relief form member is attached to aprepared structural wall to create an architectural trim, the formmember comprising; structural elements comprising; a first sideconnected wire assembly; a second side connected wire assembly; thefirst and second side connected wire assemblies being lengthwiseoppositely positioned relative to each other whereby each of themdefines a side height and a corner of the relief form member andtogether they define a width of the relief form member and an insidespace; fastenings at selected intervals connecting the structuralelements to keep them together in a predetermined relief formconfiguration
 2. The prefabricated relief form member of claim 1 furtherwherein the fastenings are discrete glue spots applied to encapsulate aportion of the first and second side connected wire assemblies.
 3. Theprefabricated relief form member of claim 1 further wherein thefastenings are weldments.
 4. The prefabricated relief form member ofclaim 1 further wherein a sheet of paper is in place in the inside spaceof the relief form member and is fastened to the side connected wireassemblies
 5. The prefabricated relief form member of claim 1 furtherwherein a sheet of paper is in place on the inside space of the reliefform member and the fastenings are discrete glue spots placed atselected intervals along the length of the relief form member to contactand thereby attach the side connected wire assemblies to each other andto attach the paper to portions of the side connected wire assemblies.6. The prefabricated relief form member of claim 1 absent any otherstructural support member.
 7. The prefabricated relief form member ofclaim 1 wherein the structural elements further comprise at least onechannel element positioned to extend between the first and secondconnected wire assemblies and the fastenings are placed to fasten thestructural elements together.
 8. The prefabricated relief form member ofclaim 1 further wherein the said structural elements comprise a firststepped structure and further wherein the first stepped structure is seton top of a second stepped structure the second stepped structure havingstructural elements comprising at least a first and second sideconnected wire assembly which define a side height and a corner of thesecond stepped structure and together they define a width of the secondstepped structure which is wider than the width of the first steppedstructure and an inside space and the fastenings include fasteningsplaced to fasten the first and second stepped structures together todefine a relief form member that can be used to create an architecturaltrim element having a stepped profile.
 9. The prefabricated relief formmember of claim 4 in which the paper is recycled paper.
 10. Theprefabricated relief form member of claim 8 further wherein a sheet ofpaper is in place in the inside space of each of the first and thesecond stepped structures and is fastened to the side connected wireassemblies.
 11. The prefabricated relief form of claim 8 wherein atleast one channel element is in place between the first and secondconnected wire assemblies of the second stepped structure.
 12. Theprefabricated relief form member of claim 8 wherein at least one channelmember is in place between the first and second connected wireassemblies of the first stepped structure.
 13. A prefabricated reliefform member for receiving and retaining a cementitious coating when therelief form member is attached to a prepared structural wall to createan architectural trim, the form member comprising; structural elementscomprising at least; a first side corner aid; a second side corner aid;the first and second side corner aids being lengthwise oppositelypositioned relative to each other whereby each of them defines a sideheight and a corner of the relief form member and together they define awidth of the relief form member and an inside space; fastenings atselected intervals connecting the structural elements to keep themtogether in a predetermined relief form configuration.
 14. Theprefabricated relief form member of claim 13 further wherein thefastenings are discrete glue spots applied to encapsulate a portion ofthe first and second side corner aids.
 15. The prefabricated relief formmember of claim 13 further wherein the fastenings are weldments.
 16. Theprefabricated relief form member of claim 13 further wherein a sheet ofpaper is in place in the inside space of the relief form member and isfastened to the side corner aids.
 17. The prefabricated relief formmember of claim 13 further wherein a sheet of paper is in place on theinside space of the relief form member and the fastenings are discreteglue spots placed at selected intervals along the length of the reliefform member to contact and thereby attach the side corner aids to eachother and to attach the paper to portions of the side corner aids. 18.The prefabricated relief form member of claim 13 absent any otherstructural support member.
 19. The prefabricated relief form member ofclaim 13 wherein the side corner aids are not modified in form.
 20. Theprefabricated relief form member of claim 13 wherein the side corneraids are modified in form having the angle between leg portionsenlarged.
 21. The prefabricated relief form member of claim 13 whereinthe structural elements comprise at least one channel element positionedto extend between the first and second side corner aids and thefastenings are placed to fasten the structural elements together. 22.The prefabricated relief form member of claim 13 further wherein thesaid structural elements comprise a first stepped structure and furtherwherein the first stepped structure is set on top of a second steppedstructure the second stepped structure having structural elementscomprising at least a first and second side corner aid which define aside height and a corner of the second stepped structure and togetherthey define a width of the second stepped structure which is wider thanthe width of the first stepped structure and an inside space and thefastenings include fastenings placed to fasten the first and secondstepped structures together to define a relief form member that can beused to create an architectural trim element having a stepped profile.23. The prefabricated relief form member of claim 16 in which the paperis recycled paper.
 24. The prefabricated relief form member of claim 21wherein at least one channel element is positioned to extend between thefirst and second side corner aids of the second stepped structure andthe channel element and the fastenings fasten the channel element ateach of its sides to one of the said side corner aids.
 25. Theprefabricated relief form member of claim 24 in which the at least onechannel element is a corner aid that has been modified in form byopening the angle between the legs
 26. A prefabricated relief formmember for receiving and retaining a cementitious coating when therelief form member is attached to a prepared wall to create anarchitectural trim, the relief form member comprising; at least a firstside corner aid and a second side corner aid being lengthwise oppositelypositioned relative to each other whereby each of them defines a heightand a corner of the relief form member and together they define a widthof the relief form member and an inside space; fastenings at selectedintervals along the length of and contacting a portion of the first andsecond side corner aids to fasten each of them to one of (a) the other(b) one or more other structural members made from additional corner aidor (c) both (a) and (b).
 27. The prefabricated relief form member ofclaim 26 further wherein at least one additional corner aid having beenwidened in profile and defining a channel corner aid is positioned toextend between the first and second side corner aids for overlapping ofa portion of each of them; the fastenings contact the first side corneraid and the at least one channel corner aid and the second side corneraid and the at least one channel corner aid respectively.
 28. Theprefabricated relief from member of claim 26 further wherein the atleast one channel corner aid is formed with a curved shape to bring itclose to the first and second corner aids where they overlap the atleast one channel corner aid in order to facilitate the fastening. 29.An architectural trim comprising a relief form member fabricated fromstructural elements comprising lengths of connected wire assembliesfastened together with fastenings to define a profile; and cementitiousmaterial applied over the relief form member to define a finished shapeand surface.
 30. The architectural trim of claim 29 wherein theconnected wire assemblies are lengths of corner aid.
 31. Thearchitectural trim of claim 29 wherein the structural elements arelengths of corner aid comprising at least; a first side corner aid; asecond side corner aid; the first and second side corner aids beinglengthwise oppositely positioned relative to each other whereby each ofthem defines a side height and a corner of the relief form member andtogether they define a width of the relief form member and an insidespace; fastenings at selected intervals connecting the structuralelements to keep them together in a predetermined relief formconfiguration.
 32. The architectural trim of claim 31 further whereinthe fastenings are discrete glue spots applied to encapsulate a portionof the first and second side corner aids.
 33. The architectural trim ofclaim 31 further wherein the fastenings are weldments.
 34. Thearchitectural trim of claim 31 further wherein a sheet of paper is inplace in the inside space of the relief form member and is fastened tothe side corner aids.
 35. The architectural trim of claim 31 furtherwherein a sheet of paper is in place on the inside space of the reliefform member and the fastenings are discrete glue spots placed atselected intervals along the length of the relief form member to contactand thereby attach the side corner aids to each other and to attach thepaper to portions of the side corner aids.
 36. The architectural trim ofclaim 31 absent any other structural support member.
 37. Thearchitectural trim of claim 31 wherein the side corner aids are notmodified in form.
 38. The architectural trim of claim 31 wherein theside corner aids are modified in form having the angle between legportions enlarged.
 39. The architectural trim of claim 31 furtherwherein the said structural elements comprise a first stepped structureset on top of a second stepped structure the second stepped structurehaving structural elements comprising at least a first and second sidecorner aid which define a side height and a corner of the second steppedstructure and together they define a width of the second steppedstructure which is wider than the width of the first stepped structureand an inside space and the fastenings include fastenings placed tofasten the first and second stepped structures together to define arelief form member that can be used to create an architectural trimelement having a stepped profile.
 40. The architectural trim of claim 34in which the paper is recycled paper.
 41. The prefabricated relief formmember of claim 30 wherein at least one channel element is positioned toextend between the first and second side corner aids of the secondstepped structure and the channel element and the fastenings fasten thechannel element at each of its sides to one of the said side corneraids.
 42. The architectural trim of claim 41 in which the at least onechannel element is a corner aid that has been modified in form byopening the angle between the legs.
 43. A method of making aprefabricated relief form member for receiving and retaining acementitious coating when the relief form member is attached to aprepared structural wall to create an architectural trim, comprising;using commercially available corner aids of specific length to constructthe relief form member said corner aids comprising at least a firstcorner aid defining a first side corner aid and a second corner aiddefining a second side corner aid; positioning the first side corner aidand the second side corner aid lengthwise oppositely relative to eachother so that each of them defines a height and a corner of the reliefform member and together they define a width of the relief form memberand an inside space; fastening the first side corner aid and the secondside corner together to keep them together in a predetermined reliefform configuration.
 44. The method of claim 43 in which the fastening isdone by applying glue at selected intervals.
 45. The method of claim 43further comprising placing a sheet of paper in the inside space.
 46. Themethod of claim 43 wherein at least one additional corner aid is formedwith an opened profile to define a channel element and is placed betweenthe first and second corner aids and fastening the channel element toeach of the first and second corner aids.
 47. The method of claim 43further wherein a sheet of paper is first placed on the fixture and thecorner aids are subsequently placed on top of the sheet of paper so thatthe finished relief form member has the sheet of paper on the inside ofthe relief form member and glue is placed at selected intervals alongthe length of the relief form member to attach the paper along thelength of the corner aids.
 48. The method of claim 43 wherein the glueis applied to encapsulate portions of the first and second corner aidsand of the at least one additional edge guide where they are gluedtogether.
 49. The method of claim 47 further wherein at least oneadditional corner aid is formed with an opened profile to define achannel element and is placed between the first and second corner aidsand the fastening is by depositing glue at selected discrete intervalsfor fastening the corner aids and the channel element together forattaching the sheet of paper to the structural elements.
 50. The methodof claim 47 wherein the modifying of the additional corner aid is bysubstantially flattening it leaving it either straight or slightlybowed.
 51. A method of making an architectural trim member comprising;determining a trim profile; arranging as structural elements of aprefabricated relief form member connected wire assemblies in aconfiguration that upon application of cementitious material will enablethe trim profile to be realized; fastening the connected wire assembliestogether; applying cementitious material to realize the trim profile.52. A method of making a prefabricated relief form for use in anarchitectural trim member comprising; preparing an elongated core havinga width and a height reverse calculated from the desired dimensions ofthe trim member so that connected wire assemblies may be made into aprefabricated relief form appropriate to realize the trim member;placing connected wire assemblies having a corner and legs extendingfrom the corner on the core so that they are positioned lengthwiseoppositely relative to each other with on leg extending over the top ofthe core and one leg extending adjacent the side of the core; fasteningthe connected wire assemblies together.
 53. The method of claim 52wherein before the connected wire assemblies are put in place on thecore a sheet of paper is put on the core, the sheet of paper extendingover the top of the core and down the sides of the core.
 54. The methodof claim 52 wherein the fastenings are glue deposits place at selectedintervals along the length of the connected wire assemblies.
 55. Themethod of claim 52 wherein the connected wire assemblies are side corneraids.
 56. The method of claim 53 wherein the connected wire assembliesare side corner aids and the fastening is done by applying glue atselected intervals along the length of the sidecorner aids to connectthem and also to adhere to the paper sheet.
 57. The method of claim 56further wherein a channel member is placed on the top of the core afterthe sheet of paper is put in place on the top of the core and the sidecorner aids are put in place either before or after the channel memberis put in place.
 58. The method of claim 57 in which the channel memberis a channel corner aid.
 59. The method of claim 52 wherein a luralityof brackets are placed on top of the connected wire assemblies to fixthem in place.
 60. the method of claim 52 wherein the relief form isattached to a wall and cementitious material is applied to create thearchitectural trim member.